Nonwoven decorative ribbons



March 13, 1956 D. J. DAVID ETAL NoNwovEN DECORATIVE RIBBoNs Filed DCT..7, 1953 United States Patent NONWDVEN DECORATIVE RIBBONS Donald l.David, Lakeland, and Robert H. Hanson, New Canada rTownship, RamseyCounty, lVIinn., assignors to Minnesota Mining & Manufacturing Company,St. Pani, Minn., a corporation of Delaware Application October 7, 1953,Serial No. 384,624

4 Claims. (Cl. 15453.6)

This invention relates to novel non-woven decorative ribbons of thepicot type, having pearl-edges formed of projecting fiber loops.

These ribbons are and must be individually manufactured, asdistinguished fromy ribbons that can be slit from fabric webs. A featureof the invention is that the ribbons have a structural design such thatthey are capable of being manufactured in a relatively simple andinexpensive manner and without the need of complicated equipment.

A further feature is that a great variety of ribbons can be produced bysimple Variations in the manufacturing operation, and many differentcolor combinations are easily obtained.

One type of ribbon is a narrow ribbon (less than onehalf inch width) ofadequate tensile strength and knot strength for use in tying packages inplace of using string or woven ribbon; which is inexpensive and yetnovel and attractive in appearance. Other types can be made which arewider and more elaborate and can be used in fashioning ornamental bowsand pompons for decorating de luxe gift packages, floral corsages,bouquets, wreaths, potted plants, and the like. These ribbons are notdamaged by contact with water, which is a very desirable feature forflorist usage as flowers are often wet or moist. They have goodworkability, are non-puckering when looped or tied into a bow, and thebows and loops have the proper combination of resiliency and stiffnessto be well-formed, iirm and crisp, and yet are flexible and yieldable.

The lengthwise tensile properties of the ribbon are primarily due to alayer of lineally-aligned viscose-rayon (regenerated cellulose)filaments that are continuous and extend from end to end of the tape.These filaments have a hair-like flneness and a large number areemployed in any given ribbon. They may extend uniformly across the widthof the filament layer, or constitute two or more spaced-apart strips.They may be present in the form of twisted yarns, or in the form of towsthat are spread out. In addition to their important mechanical functionin the structure, these lineally-aligned continuous-filaments have adecorative function that is equally important. They can be colored invarious ways and they provide a shiny lengthwise striping effect.

The rayon iilaments may be coated with a water-resistant organic-polymerbinder sizing, such as a suitable vinyl resin, which provides an almostimperceptible flexible coating that serves to hold the filaments inposition and prevents fraying, but does not materially stiien the fabricor conceal the filament structure. This sizing may be colored andthereby provide the desired colored appearance of the filament strip orstrips, or it may be clear and transparent to reveal the coloration ofthe filaments when dyed filaments are employed. The sizing polymer maybe included in a dye bath and the filaments simultaneously dyed andcoated. The use of a binder sizing is not necessary when the filamentsare present in the form of twisted yarns. v

The filament layer carries a superimposed open-mesh 2,738,298 PatentedMar. 13, 1956 layer bonded thereto (preferably autogenously by directunion with the sizing if present or by direct union with the filaments,as distinguished from use of an extraneous adhesive to glue themtogether). This open-mesh layer is formed of a plurality of continuouslineally-directed sinuous mono-fibers, which are mutually offset fromeach other and are fused together at their crossing points to form aunitary network having a lineally repetitive pattern.

This network serves an essential mechanical function in holding togetherin crosswise direction the elements of the filament layer, in providingan adequate crosswise strength for the composite ribbon, and inproviding a desired degree of crosswise andlenghtwise stiiiness incombination with adequate flexibility and resiliency. lt also servesk'an essential decorative function in providing an ornamental designthat pleasingly combines with the lineal striping appearance of thefilament layer. Having an open mesh, it permits the latter to be seenthrough it, and it` can be given a contrasting coloration if desired. Afurther essential function, both mechanical and decorative, is that ofproviding loops that project beyond the sides of the filament layer and.form pearl-edges in the ribbon, thereby making it a picot ribbon.

The network does not carry the lengthwise strain when the ribbon ispulled or jerked, the continuous-iilaments primarily carrying the loadand preventing the network from being pulled out and distorted. Thefilaments also provide a degree of elasticity and resiliency thatimproves shock resistance. They are present in sufficient number suchthat the ribbon has a lengthwise tensile strength of at least tenpounds.

The mono-fibers of the network are composed of cellulose acetate, andthey have a thickness in the range of about l to 4 mils, in contrastwith the much finer size of the lineal filaments. They can be formed andcombined in a virtually simultaneous operation, by extruding a viscouscellulose acetate solution from the holes of a spinneret head,downwardly upon the filament layer that is travelling on an endlessbelt, the spinneret head being reciprocated transversely to lay theiibers in an overlapping sinuous manner. The wet fibers coalesce or fuseat their crossing points and also bond to the sizing coating of thefilaments, or directly to the filaments when unsized yarns are employed,being activated to a soft and adhesive state by the solvent; resultingin a unitary and non-tacky ribbon product upon subsequent evaporation ofthe solvent in an oven and stripping of the ribbon from the castingbelt. These extruded mono-fibers have a flattened base due to gravityand to flow of the viscous material, and are several times as wide asthick; and this feature is valuable both from the physical anddecorative standpoints.

The general process of forming mono-liber fabrics by extrusion of atemporarily plastic mono-fiber composition from an oscillating spinneretupon an endless moving belt, including'simultaneous lamination to aninterposed Woven foundationy fabric carried upon the belt, if desired,was published more than fifty years ago in British specification No.17,549 (1898). Rayon filaments and cellulose acetate have been wellknown and commercially available for a great many years. However, to thebest of our knowledge, no one had previously conceived of using thatkind of process and these materials in combination, to manufacture aribbon material of the type which we have invented and which is uniquelydifferent from any ribbon heretofore known to the trade so far as wehave been able to determine.

The invention can best be described in further detail in connection withthe accompanying drawing.

In the drawing:

Fig. 1 is a schematic perspective view of apparatus for manufacturingthe ribbon product and also serves as a flow-sheet illustrating theprocess as applied in the making of a particular type of ribbon.

Figs. 2 and 3 are plan views of two additional illustrative ribbonproducts.

Referring to Fig. l, there is shown a complete manufacturing process formaking a narrow ribbon (suitable for use as a tying ribbon) comprised ofa uniform single strip of untwisted continuous filaments coated with abinder sizing and bonded to a network formed of ve sinuous mono-fibersthat are uniformly offset and are fused at their crossing points, eachmono-fiber winding across the full width of the tape.

A tow l consistingy of a large number of viscose-rayoncontinuous-filaments hunched together in untwisted relationship, isshown being drawn into the feed end of the apparatus, coming from arotating package or creel (not shown). The laments are drawn over andunder a series of smoothing bars 2 which spread them out in a flat stripand cause the laments to lie approximately parallel to one another. Thestrip of filaments then passes between two teeth of the positioning rake3, to align the filaments and produce the desired width, and then overthe coating roll Li which dips into the bath 5 which contains dye andsizing resin dissolved in a volatile solvent. The coating solution istransferred from the roll to the filament layer and penetrates and coatsthe filaments so as to simultaneously dye the filaments and bind themtogether. The filament strip is then drawn under smoothing bar d andover smoothing bars '7, and then under the positioning bar 3, located sothat the strip will be in proper position to meet the upper surface ofthe endless carrier belt 9 as it passes over supporting roll lf3.

This carrier belt moves in a clockwise direction to and through thedrying oven ll (passing around rolls therein, not shown) and emergesfrom the bottom of the oven, passes under roll i2, up to and around roll13, and then up to and around the supporting roll where it meets theentering strip of filaments as just described. The belt may be a metalscreen, or a sheet material (such as a polyethylene film reinforced withglass filaments and supported on a screen), adapted to receive and holdthe ribbon elements and from which the finished ribbon can be stripped.The belt is driven at a constant predetermined speed by driving means(not shown).

A vertical spinneret head ifi is mounted above the carrier belt so as tobe positioned above the strip of filaments and just beyond thesupporting roll 10. The spinneret head is fed with a viscous celluloseacetate solution through flexible tube 15 which is connected through afeed line to a pump (not sh wn) that is adjusted to feed the solution.at the desired rate. The spinneret extruder plate, in this illustrativecase, has five holes, uniformly spaced, positioned in a straight linethat is parallel to the direction of motion of the carrier belt, so asto extrude ve viscous mono-fibers in lineal alignment upon the strip offilaments. The Spinnerei is carried by a bar (not shown) that. isreciprocated transversely of the belt by a suitably driving mechanism(not shown), the stroke or travel being adjusted to lay down theextruded monotioers in the desired band width, somewhat wider than thestrip of laments.

The resultant effect of the lineal motion of the strip ot' filaments andthe transverse motion of the spinneret with its lineally aligned holes,is to lay the viscous monobers in a sinuous manner, each mono-iberadvancing in a wave-like direction from edge to edge and being crossedby each of the others. The axes of the Wave lines are lineal andparallel, and hence the mono-fibers are lineallydirected althoughmutually offset and overlapping. rthe fiber turns, where direction isreversed, 'Jroiect beyond the edges of the strip of filaments andprovide loops forming pearl-edges and a picot ribbon structure. Theviscous mono-fibers merge together at their crossing points to fuse thefibers, resulting in a unitary network. The viscous fibers in beingextruded upon the strip of filaments and the carrier belt, are liattenedon the contacting bottom portions, due to gravity and viscous flow ofmaterial, thereby increasing the area of contact, and a strong bond iseffected with the binder sizing coating which is still in a viscous andtacky state, thereby unifying the two layers. The solvents in themono-fibers and in the sizing composition are selected to producecompatibility adequate to cause a strong bonding without excessive iiowof the mono-fiber at the point of contact that would weaken it.

The freshly formed ribbon product 16 is shown moving toward the dryingoven, where the volatile solvents present in the viscous mono-fibers andin the sizing coating are evaporated and the elements of the ribbon arethus set-up to their dry final state. The ribbon product i7 is strippedfrom the carrier belt as the latter moves from roll 12 and is drawn to awind-up roll (not shown).

lt is obvious that a number of ribbons can be made simultaneously withthis type of apparatus, using a corresponding number of spinneret heads,but for simplicity the making of 4a single ribbon has been illustrated.

Many different structural designs can be achieved by varying therelative speeds of the spinneret and the .carrier belt, the mode ofreciprocation of the spinneret (thus a harmonic motion will produce adifferent pattern than a non-harmonic motion), and thc number andarrangement of the extrusion holes. The distance of the spinneret abovethe belt, and the viscosity of the extruded solution, will also effectthe laying down of the monofibers and the precise pattern. instead ofthe filaments being uniformly spread in a single strip, they may bedivided to form two or more spaced-apart strips. Twisted filament yarnsmay be used, forming either a single strip or two or more spaced-apartstrips. ln these latter cases the binder sizing may be omitted, as theviscous mono fibers will press against the yarns and flow so as topenetrate the filament structure, interlocking and physically anchoringto the filaments that are contacted, the twist holding the filamentstogether and bringing them into position for bonding at various pointsalong their lengths.

Details involved in making a preferred tying ribbon of the Fig. l typedescribed above are as follows: The ribbon had a total width of LV1@inch and a tensile strength of i9 pounds. The continuous-filament striphad a width of Mi inch and was formed from a 2200 denier tow consistingof 1466 untwisted viscose-rayon continuous-filaments of high tenacity(3.1 grams per denier). The sizing bath consisted of a 15% solution of a87:13 copolymer of vinyl chloride and vinyl acetate in a solvent mixtureof equal parts of methyl ethyl ketone and toluene. The bath contained adye to impart the desired shade and intensity of color (for example,0.5% of Grasol yellow dye, sold by Geigy Company, lne). The spinnerethad five lineally aligned extrusion holes spaced 1/s inch apart, cachhole had a diameter of 0.006 inch (6 mils), the spinneret reciprocationdistance was 0.2125 inch, the frequency was 2145 complete cycles perminute, and the spinneret was positioned to provide a vertical distanceof inch to the belt. (It will be noted that this reciprocation distanceis less than the width of tbe ribbon, which is accounted for by the factthat the rapidly oscillating spinneret throws the extruded viscousmono-fibers an additional distance.) The carrier belt moved at a speedof 73.5 feet per minute. The cellulose acetate solution was extruded atthe rate of 10.5 cc. per minute (all five holes). The unpigmentedcellulose acetate solution consisted of 21.1% by weight of celluloseacetate (38% acetyl content, viscosity range of 45 to 55 seconds by A.S. T. M. method DSH-48 formula A), 6.32% of' triphenyl phosphate(plasticizer), 65.6% of acetone, and 6.95% of ethyl alcohol. Thissolution was thoroughly mixed with pigment to produce the desiredcoloration. For making yellow fibers, the composition consisted ofpounds.

100 parts by weight of the cellulose acetate solution, 0.17 part oftitanium dioxide pigment paste (36.4% pigment milled with `63.6%tricresyl phosphate), and 0.57 part of yellow pigment paste (50% chromeyellow pig ment milled with 50% tricresyl phosphate). The ribbon producthad a weight of 35.8 grams per 100 lineal yards (10.1 grams duetto thecellulose acetate mono-fiber network, 22.4 grams due to theviscose-rayon filaments and 3.3 grams due to the sizing). The caliperthickness was 5.0 to 5.5 mils. The caliper thickness of the mono-berswas 2.6 Vto 2.9 mils. The lineal tensile strength was 19 The ribbonstructure permitted an easy crosswise collapse in tying knots so as topermit of tying small hard knots; this property beingy due to thecombinative or cooperative effect of several factors present in thestructure.

Fig. 2 shows a modication of the picot ribbon of Fig. 1, which is madein the same way except that eight continuous-lament twisted yarns 20,uniformly spaced from each other and lineally aligned, are employed toprovide the lament base layer upon which the sinuous mono-fibers 21 areextruded. An example of a suitable yarn is a 300 denier, 60 filament,2%/2 turns per inch, mediumtenacity viscose-rayon yarn.

Fig. 3 illustrates still another type of picot ribbon, which isespecially adapted for fashioning ornamental bows and pompons. Thisribbon has a combination striped and elaborate ligree pattern and is 7/sinch wide. The three lineal stripes 22 (two marginal stripes and acentral stripe) are spaced well apart and each stripe consists ofseveral twisted continuous-lament yarns in shoulder-to-shoulder relation(for example, eight 150 denier, 40 filament, 2V; turns per inch, viscoseyarns). The ligree network 23 bonded thereto is formed from 13 pairs ofmono-bers, extruded from a spinneret having 13 pairs of holes, each pairbeing lineally aligned, and the series of pairs of holes extendingtransversely (relative to ribbon travel direction). The lineal-directiondistance between the holes of each pair is M1 inch, and thetransverse-direction distance between successive pairs of holes is )isinch. The spinneret travels through a transverse stroke of g inch, andthe speed of oscillation is coordinated with the speed of the carrierweb so that the wave patterns of the bers extruded from each pair ofholes are 180 out of phase (the peaks of one ber being thus transverselyaligned with the valleys of the other ber). The adjacent pairs ofmono-bers overlap across the width of the ribbon to form a unitarycomposite network composed of 13 pairs of lineally-directed sinuousmono-bers bonded together to provide the full 'Mz inch width of theribbon product, the marginal ber loops extending beyond the marginallament yarn stripes to make a picot type ribbon.

An example of an attractive combination of color eects in this form ofconstruction, is one obtained by coloring the lineal yarns green (byusing a green dye in the sizing bath solution), using clear uncoloredmono-bers, and subjecting the completed ribbon to aluminum metallizingon the ber network side. The front side of the ribbon is the sidecarrying the exposed green stripes, which are opaque and conceal themetallic back. The ber network appears silvery from this front sidebecause the bers are transparent and, owing to an optical illusion,appear as though made of aluminum. Thus the front side of the ribbonexhibits green stripes against a silvery filigree is fashioned into abow and the differing appearances provide an attractive contrast.

A variety of other similar filigree ribbons can be made by varying thedetails. Preferred constructions have a width of approximately 1 to 2inches, two or more spacedapart stripes of lineally aligned laments(twisted or untwisted), and 8 to 24 pairs of the mono-bers per inchwidth of the ribbon.

What we claim is as follows:

1. A non-woven decorative picot ribbon of the character described,essentially consisting of a fiat lament layer formed of a large numberof lineally-aligned viscose-rayon continuous-filaments, and asuperimposed open-mesh layer bonded thereto and formed of a plurality ofcontinuous lineally-directed sinuous mono-bers which are mutually offsetand are fused together at their crossing points to form a unitarynetwork having a lineally repetitive pattern, the network having loopsextending beyond the sides of the lament layer to provide the ribbonwith pearledges, said mono-bers being composed of cellulose .acetate andhaving a thickness in the range of about 1 to 4 mils, and the ribbonhaving a lengthwise tensile strength of at least 10 pounds.

2. A non-woven decorative picot ribbon essentially consisting of a flatlament layer formed of a large number of lineally-aligned viscose-rayoncontinuous-filaments coated with a colored water-resistantorganic-polymer binder sizing and, autogenously bonded thereto, asuperimposed open-mesh layer formed of a plurality. of continuouslineally-directed sinuous mono-bers which are mutually offset and arefused together at their crossing points to form a unitary network havinga lineally repetitive pattern, the network having loops extending beyondthe sides of the filament layer to provide the ribbon with pearl-edges,said mono-bers being composed of cellulose acetate and having athickness in the range of about 1 t0 4 mils, and the ribbon having alengthwise tensile strength of at least 10 pounds.

3. A ribbon according to claim 2 wherein the lament layer is uniformacross its width and composed of untwisted and unspaced laments forminga single strip nearly as wide as the total width of the ribbon, and eachmono-ber winds across the full width of the tape, the ribbon having awidth of. less than one-half inch.

4. A non-woven decorative picot ribbon having a width of approximately lto 2 inches and essentially consisting of a at lament layer formed of aplurality of spacedapart lineal stripes each consisting of a largenumber of lineally-aligned viscose-rayon continuous filaments, and asuperimposed open-mesh layer bonded thereto and formed of from 8 to 24pairs, per inch of ribbon width, of lineally-directed sinuous mono-bers,the mono-bers of each pair having wave patterns out of phase, and thepairs being laid down side by side with adjacent pairs fused together atmono-ber crossing points to provide a unitary ligree design having alineally repetitive pattern and having loops extending beyond thestripes to provide the ribbon with pearl-edges, said mono-bers beingcomposed of cellulose acetate and having a thickness in the range ofabout 1 to 4 mils, and the ribbon having a lengthwise tensile strengthof at least 10 pounds.

References Cited inthe le of this patent UNITED STATES PATENTS GreatBritain 1898

1. A NON-WOVEN DECORATIVE PICOT RIBBON OF THE CHARACTER DESCRIBED,ESSENTIALLY CONSISTING OF A FLAT FILAMENT LAYER FORMED OF A LARGE NUMBEROF LINEALLY-ALIGNED VISCOSE-RAYON CONTINUOUS-FILAMENTS, AND ASUPERIMPOSED OPEN-MESH LAYER BONDED THERETO AND FORMED OF A PLURALITY OFCONTINUOUS LINEALLY-DIRECTED SINUOUS MONO-FIBERS WHICH ARE MUTUALLYOFFSET AND ARE FUSED TOGETHER AT THEIR CROSS POINTS TO FORM A UNITARYNETWORK HAVING A LINEALLY REPETITIVE PATTERN,THE NETWORK HAVING LOOPSEXTENDING BEYOND THE SIDES OF THE FILAMENT LAYER TO PROVIDE THE RIBBONWITH PEARLEDGES, SAID MONO-FIBERS BEING COMPOSED OF CELLULOSE ACETATEAND HAVING A THICKNESS IN THE RANGE OF ABOUT 1 TO 4 MILS, AND THE RIBBONHAVING A LENGTHWISE TENSILE STRENGTH OF AT LEAST 10 POUNDS.